High heat polycarbonate compositions

Abstract

Metallized articles comprising polycarbonate compositions are disclosed. The compositions include at least one first polycarbonate useful for high heat applications; and a second Bisphenol A polycarbonate. The compositions can include one or more additives. The compositions can be used to prepare articles of manufacture, and in particular, automotive bezel.

1 . A metallized article comprising a thermoplastic composition comprising:
 (a) a first polycarbonate that includes structural units derived from at least one of:   
       
         
           
           
               
               
           
         
       
       wherein R a  and R b  at each occurrence are each independently halogen, C 1 -C 12  alkyl, C 1 -C 12  alkenyl, C 3 -C 8  cycloalkyl, or C 1 -C 12  alkoxy; p and q at each occurrence are each independently 0 to 4; R 13  at each occurrence is independently a halogen or a C 1 -C 6  alkyl group; c at each occurrence is independently 0 to 4; R 14  at each occurrence is independently a C 1 -C 6  alkyl, phenyl, or phenyl substituted with up to five halogens or C 1 -C 6  alkyl groups; R g  at each occurrence is independently C 1 -C 12  alkyl or halogen, or two R g  groups together with the carbon atoms to which they are attached form a four-, five, or six-membered cycloalkyl group; t is 0 to 10; and x:y is 1:99 to 99:1; and
 (b) a second polycarbonate that is a Bisphenol A polycarbonate having a Mw of 17,000 g/mol [ ± 1,000 g/mol] to 24,000 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; 
 wherein the composition has a melt viscosity of less than 375 Pa·s, measured in accordance with ISO 11443 at 300° C. at a shear rate of 1500 s −1 ; 
 wherein the composition has a heat deflection temperature of at least 150° C., measured at 0.45 MPa in accordance with ISO 75. 
 
     
     
         2 . The article of  claim 1 , wherein the article has one or more of the following properties: a minimum haze onset temperature of 150° C.; achieves a GT0 metal adhesion rating when measured in accordance with ASTM 3359/ISO 2409; and exhibits 0% corrosion when stored for 240 hours at 98% relative humidity at 40° C., in accordance with DIN 50017. 
     
     
         3 . The article of  claim 1 , wherein the first polycarbonate comprises at least 18 mol % structural units derived from BPA, and has a Tg of at least 170° C. 
     
     
         4 . The article of  claim 1 , wherein the first polycarbonate comprises 31 mol % to 35 mol % structural units derived from PPPBP. 
     
     
         5 . The article of  claim 1 , wherein the first polycarbonate is: a para-cumylphenol end-capped polycarbonate comprising structural units derived from PPPBP and BPA, having a Mw of 17,000 g/mol [ ± 1,000 g/mol] to 20,000 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards. 
     
     
         6 . The article of  claim 1 , wherein the second polycarbonate is: a PCP end-capped linear BPA polycarbonate having a Mw of 18,200 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; a PCP end-capped linear BPA polycarbonate having a Mw of 18,800 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; a linear BPA polycarbonate having a Mw of 21,700 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; a PCP end-capped linear BPA polycarbonate having a Mw of 21,800 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards; or a PCP end-capped linear BPA polycarbonate having a Mw of 21,900 g/mol [ ± 1,000 g/mol], as determined by GPC using BPA polycarbonate standards. 
     
     
         7 . The article of  claim 1 , wherein the second polycarbonate is a para-cumylphenol end-capped linear Bisphenol A polycarbonate produced via interfacial polymerization, having a Mw of 18,200 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards. 
     
     
         8 . The article of  claim 1 , wherein the second polycarbonate is a para-cumylphenol end-capped linear Bisphenol A polycarbonate produced via interfacial polymerization, having a Mw of 18,800 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards. 
     
     
         9 . The article of  claim 1 , wherein the second polycarbonate is a linear Bisphenol A polycarbonate produced via melt polymerization, having a Mw of 21,700 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards. 
     
     
         10 . The article of  claim 1 , wherein the second polycarbonate is a para-cumylphenol end-capped linear Bisphenol A polycarbonate produced via interfacial polymerization, having a Mw of 21,800 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards. 
     
     
         11 . The article of  claim 1 , wherein the second polycarbonate is a para-cumylphenol end-capped linear Bisphenol A polycarbonate produced via interfacial polymerization, having a Mw of 21,900 g/mol [ ± 1,000 g/mol] as determined by GPC using BPA polycarbonate standards. 
     
     
         12 . The article of  claim 1 , wherein the composition comprises: 60 wt % to 72 wt % of the first polycarbonate, based on total weight of the composition; and 40 wt % to 28 wt % of the second polycarbonate, based on total weight of the composition. 
     
     
         13 . The article of  claim 1 , wherein the composition comprises: 64.0 wt % of the first polycarbonate; 35.6 wt % of the second polycarbonate; and 0.4 wt % of one or more additives. 
     
     
         14 . The article  claim 13 , wherein the 0.4 wt % additives comprises: 0.04 wt % octadecyl 3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate; 0.08 wt % tris(di-t-butylphenyl)phosphite; and 0.3 wt % Palmitic/Stearic Acid (50/50) ester of dipenta/pentaerythritol. 
     
     
         15 . The article of  claim 1 , wherein the composition has a melt viscosity of less than 350 Pas, measured in accordance with ISO 11443 at 300° C. at a shear rate of 1500 s −1 ; wherein the composition has a heat deflection temperature of at least 160° C., measured at 0.45 MPa in accordance with ISO 75; wherein the composition has a notched Izod impact strength (NII) of at least 8 kJ/m 2  or at least 9 kJ/m2 at 23° C., measured in accordance with ISO 180; or wherein a molded sample of the composition has at least 60% ductility in a multi-axial impact test at 23° C., measured in accordance with ISO 6603; or any combination thereof. 
     
     
         16 . The article of  claim 1 , wherein a 3.0 mm plaque comprising the composition, metallized with a 100 nm to 150 nm thick aluminum layer using a physical vapor deposition process, and protected with a plasma-deposited siloxane hard-coat of 50 nm, has a minimum haze onset temperature of 160° C. 
     
     
         17 . The article of  claim 16 , wherein the plaque has a minimum haze onset temperature of 165° C.; wherein the plaque achieves a GT0 metal adhesion rating when measured in accordance with ASTM 3359/ISO 2409; or wherein the plaque exhibits 0% corrosion when stored for 240 hours at 98% relative humidity at 40° C., in accordance with DIN 50017. 
     
     
         18 . The article of  claim 1 , wherein a 1.5 mm plaque comprising the composition, metallized with a 100 nm to 150 nm thick aluminum layer using a physical vapor deposition process, and protected with a plasma-deposited siloxane hard-coat of 50 nm, has a minimum haze onset temperature of 150° C. 
     
     
         19 . (canceled) 
     
     
         20 . The article of  claim 1 , wherein a metallized part comprising the composition has an L* of 15 or less when measured using a spectrophotometer in reflection mode with specular light excluded. 
     
     
         21 . The article of  claim 1 , selected from instrument panels, overhead consoles, interior trim, center consoles, panels, quarter panels, rocker panels, trim, fenders, doors, deck lids, trunk lids, hoods, bonnets, roofs, bumpers, fascia, grilles, minor housings, pillar appliqués, cladding, body side moldings, wheel covers, hubcaps, door handles, spoilers, window frames, headlamp bezels, headlamps, tail lamps, tail lamp housings, tail lamp bezels, license plate enclosures, roof racks, circuit breakers, electrical and electronic housings, and running boards, or any combination thereof.